MAN B&W Diesel A/S Production Recommendation

Info No.: Ident No.:

3 93 031 General Information Regarding 0 59 80 53 - 0.
Scale: Size: Repair of Grey Iron Castings Page No.:
A4 1 (3)
Similar Drawing No.: Replacement for Ident. No.:
Date Des. Chk. Appd. Photo date A.C. Change / Replacement C.No.
02081979 NHM NHM 0
08101979 NHM NHM 10101979 1
08121983 BOH BOH 15121983 2
22121983 BOH BOH 11011984 3
14121993 RLJ RLJ 14121993 Z4 4
04121998 CTS KET 18121998 Z2 Updated to new form 5
6
7
8
Replaced by Ident. No.: 9
Suppl. Draw:

Contents

1. Repair policy
2. References
3. Repair by grinding
4. Repair by plugging
5. Repair by inserting a plate
6. Repair by "metalocking"
7. Repair by welding
8. Repair by plastic steel

1. Repair policy

Owing to the often complex design and the large size of grey iron castings for diesel
engines, some repair possibilities will and must be permissible in order to avoid rejections
and expensive re-production.

The main criteria for deciding on possible repairs are:

a) For a defect in an obviously unloaded part of the component, the surveyors’

acceptance of the repair must be obtained beforehand.

b) For a defect in a loaded part of the component, approval of the repair should be
obtained from the designer, if possible, before the surveyors are involved in the
matter.

A report with a drawing or a photo showing the defective area and stating the repair method
recommended or applied must always be prepared, and copies given to the parties involved,
the original being filed in the Q.C. Department.
MAN B&W Diesel A/S Production Recommendation
Info No.: Ident No.:
3 93 031 General Information Regarding 0 59 80 53 - 0.
Scale: Size: Repair of Grey Iron Castings Page No.:
A4 2 (3)
Date Des. Chk. Appd. Photo date A.C. Change / Replacement C.No.
04121998 CTS KET 18121998 Z2 Updated to new form 5

2. References

In this instruction reference is made to the following MAN B&W Standard Sheets:

EN71P; Plugs
EN71S; Plugs

3. Repair by grinding

Grinding away defective material is generally accepted provided the strength and the
tightness of the component remains satisfactory.

The grinding must be made smooth, with smooth transitions to the surrounding material.

The final appearance of the component must be taken into account when determining the
extent of the grinding operation.

4. Repair by plugging

Minor defects can be repaired by drilling-out the defective material, cutting a thread in the
hole and fitting a plug-screw. The diameter and thread chosen must be suitable for the
insertion of a standard screw made of grey cast iron (see for instance MAN B&W Standard
Sheet EN71P; Plugs and MAN B&W Standard Sheet EN71S; Plugs).

5. Repair by inserting a plate

Where defective material is found on flanges, foundation parts or the like, a plate of cast
iron can in many cases be inserted or screwed-on after the defective material has been
removed by machining.

The plate must fit tightly in the machined area of the component.

This repair method may also be used in the case of broken corners, missing cast-on lugs or
the like.

6. Repair by "metalocking"

"Metalock" is the trade name for a special method for the repair of fractures in cast iron
components. The method consists of specially-formed keys made of an alloy with low
thermal expansion. The keys are inserted in drilled slots, transverse to the fracture, by cold
working into the parent material.
MAN B&W Diesel A/S Production Recommendation
Info No.: Ident No.:
3 93 031 General Information Regarding 0 59 80 53 - 0.
Scale: Size: Repair of Grey Iron Castings Page No.:
A4 3 (3)
Date Des. Chk. Appd. Photo date A.C. Change / Replacement C.No.
04121998 CTS KET 18121998 Z2 Updated to new form 5

The repair of a new casting by means of the "metalock" system is not generally accepted
and must only be performed if acceptance has been obtained from the designer, the
customer, and the Classification Society.

However, this repair method is generally accepted for components damaged in service -
even on rather highly loaded parts - provided acceptance has been obtained from the
Classification Society and the owner.

7. Repair by welding

Repair of new cast iron components for diesel engines by welding is not permitted unless
the designer has approved this in writing.

8. Repair by plastic steel

Small defects in areas for sealing rings can, where other repair methods are not deemed
feasible, be repaired with plastic steel type:

"Devcon Steel (R) Putty (A)," or "Velodur (Durametal)"

To ensure that the plastic steel adheres firmly to the surface, the defective material is to be
ground away so that a rough surface remains - if necessary, this can be achieved by drilling
a number of small holes.